Online recipe synchronization in a real-time batch executive environment

ABSTRACT

A method of executing a batch process in a manufacturing environment according to a product recipe, such that the product recipe specifies a plurality of actions and a plurality of parameters, includes performing at least one action of the batch process corresponding to a first version of the product recipe, receiving a second version of the product recipe, such that the second version of the product recipe is distinct from the first version of the product recipe, suspending the execution of the batch process prior to completion of the batch process, and resuming the execution of the batch process according to the second version of the product recipe.

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Patent App. No.60/974,368 entitled “Online Recipe Synchronization in a Real-Time BatchExecutive Environment,” filed Sep. 21, 2007, the disclosure of which ishereby expressly incorporated herein by reference.

FIELD OF TECHNOLOGY

The present invention relates generally to process control networks and,more particularly, to a batch execution engine capable of acceptingchanges to currently running batches.

DESCRIPTION OF THE RELATED ART

Process control systems, such as those that use batch processingtechniques to produce large quantities of pharmaceuticals, chemicals,beverages, paint, or any other product, generally include one or morecentralized process controllers communicatively coupled to one or morefield devices which may be, for example, valve positioners, switches,sensors (such as temperature, pressure and flow rate sensors), etc.These field devices may be associated with control equipment such as,for example, valves, pumps, mixing units, etc., may perform physicalcontrol functions (such as opening or closing a valve, turning a pump ormixing unit on and off, etc.) within a process control system, may takemeasurements within the process control system for use in controllingthe operation of the process or may perform any other desired functionwithin the process control system. Generally speaking, the processcontrollers receive signals indicative of measurements made by one ormore field devices and/or other information pertaining to the fielddevices, use this information to implement a typically complex controlroutine and generate control signals that are sent via the signal linesor buses to the field devices to control the operation of the processcontrol system.

Furthermore, the process controllers are generally coupled via a datahighway, such as an Ethernet bus, to one or more workstations and otherdevices. These other devices typically run other applications orprograms that use the information provided by the one or morecontrollers to provide other process control functions, such asproviding a user interface to the control routine, enabling modificationor updating of the control routine, interfacing with the field devices,storing historical process control data, controlling or restricting useraccess, etc. In some large process control systems, one or moreworkstations located at a remote site may be coupled to the data highwayvia a further communication network, such as an Internet connection, asatellite or cellular communication link, a radio link (as used inwireless Ethernet connections), etc.

Process control systems that produce batches of products typicallyinclude a graphical interface, which enables a user (e.g., an engineer)to define and store one or more basic product recipes, batch parameters,equipment lists, etc. These basic product recipes typically include asequence of process steps that are each associated with or bound to aparticular equipment list. In binding recipe process steps to particularpieces of equipment, the user (e.g., an operator) explicitly defines,prior to the batch execution of the recipe, which piece of processcontrol equipment to be used to carry out each process step of therecipe. Additionally, each of the process steps may require a user(e.g., an operator) to define one or more input/output (I/O) batchparameter values that are used during the execution of a batch tocontrol the sequence and/or timing of equipment operations, set alarmlimits, set target control values (e.g., setpoints), etc. These I/Oparameter values may be associated with inputs and outputs that are sentto or which are received from one or more of the field devices withinthe process control system or, alternatively, may be intermediate orcalculated values that are generated by the process control systemduring the execution of a batch. Thus, in defining a batch, a user(e.g., an operator) typically uses the graphical interface to select abasic product recipe (which includes specifications that bind theprocess steps of the recipe to process control equipment) and to specifythe parameter values that are to be used during execution of the batch.For example, in a control system that produces batches of paint, a user(e.g., an operator) may interact with the graphical interface to selecta basic paint recipe such as, for example, a semi-gloss exterior latexpaint, and may specify parameter values that result in the production ofa batch of 100 gallons of a particular color of semi-gloss exteriorlatex paint.

By way of example only, a basic paint recipe may include one or moreprocess steps that add colorants or other substances to a basic paintmixture and may further include additional process steps thatmechanically blend these colorants and other substances into the basicpaint mixture. The blending and mixing process steps, or any otherprocess steps associated with the basic paint recipe, may be bound tospecific pieces of equipment within the process control system. Forexample, a first mixing step may be bound to a first blender and asecond mixing step may be bound to a second blender or, alternatively,if desired, the second mixing step may instead be bound to the firstblender. Similarly, each process step of the recipe that adds colorantto the paint mixture may be bound to a particular piece of colorantdispensing equipment.

Furthermore, in defining a batch, a user may provide a variety of I/Oparameter values such as blending times, colorant amounts, etc. that areused by the process control system during execution of the batch tocarry out the process steps specified by the batch and to achieve adesired final paint product. A user can thus produce a variety of finalpaint products including a variety of basic paint types (as specified bybasic recipes) in a variety of colors (as specified by I/O parametervalues). Of course, because conventional batch definition techniques mayalso be used to create many other types of products such aspharmaceuticals, beverages, food products, etc., the particular processsteps, equipment bound to the process steps and the I/O parameter valuesmay be varied so that the process control system produces the desiredfinal product.

In the recent years, batch execution environments have becomesignificantly more complex. For example, many modern batch processplants run several parallel batches using multiple “equipment trains,”or sets of operatively connected control equipment units necessary tophysically perform a particular batch run. Recipes have also grownlonger, with every procedural step in turn increasing in complexity.Meanwhile, measurement devices now yield better measurements of batchparameters and report these measurements in real-time or in nearreal-time to controllers and operator workstations. In particular, thesemeasurement devices may quickly and accurately detect such abnormalconditions as, for example, excessive temperature, insufficientpressure, or an unexpectedly high concentration of a particularchemical. Operators understandably wish to respond to these conditionsas quickly as possible in order to reduce product loss and to avoidharmful situations. As a result, the industry demands more flexibilityfrom batch execution environments even as the task of controllingbatches becomes increasingly more complex.

Moreover, some countries have also experienced changes in governmentregulation related to certain manufacturing methods. For example, theFood and Drug Administration of the United States (FDA) recentlylaunched the so-called Process Analytic Technology (PAT) initiative. Thestated goal of PAT is to control the manufacturing process in additionto final manufactured products. To comply with PAT requirements,manufactures must be able to assure quality at the intermediate steps ofa corresponding manufacturing process and, of course, properly andtimely respond to the detected conditions. Thus, modern batch executionenvironments must be flexible for both economic and regulatory reasons.

Unfortunately, the existing batch execution technology and methodologyfall short of meeting these demands in a cost-effective manner. Atypical process control system servicing a batch process plant maintainsrecipe information in a dedicated database. For every product, thedatabase stores a “control recipe” which may include a proceduralstructure of the recipe, recipe parameters, a list of equipment unitsrequired by the recipe, and other recipe information. In response to anoperator command or other predetermined condition, the process controlsystem retrieves a particular control recipe from the database andapplies the recipe to a selected “batch executive,” or a subsystemresponsible for executing one or more batch runs according to thereceived recipe. The batch executive saves the snapshot of the receivedversion of the recipe so that changes to the control recipe do noteffect the execution of an already running batch. In other words, thebatch executive can only execute the originally received recipe and doesnot react to the potential changes to the control recipe in the databasein real time.

Traditionally, operators have found the lifetime association between abatch executive and a single version of a recipe to be acceptable. Untilthe recent rapid changes in technology and government regulation, plantsran one or more batches with the same recipe for months at a time.Operators applied new recipes relatively infrequently and planned theintroduction of new recipes well in advance. However, the current stateof the industry demands that batch execution environments becomeresponsive to sudden and frequent changes in recipe even for thosebatches that take weeks or months to complete.

Some attempts have been made in the recent years to increase theflexibility of batch execution environments. For example, the EmersonProcess Management DeltaV™ interface tool allows operators to forcetransitions between steps of a recipe as part of the Active Step Changefeature. While the Force Transition function greatly extends operators'control over the execution of a recipe, this feature does not grantoperators control over the actual steps or logic of the recipe. ActiveStep Change additionally allows operators to initiate a run of a certainphase of a recipe as a standalone batch. However, this aspect of thefeature is similarly limited to the original definition of the recipe.Moreover, the manual operation is permitted only on the phase level.Thus, if an engineer or an operator updates a recipe which is alreadybeing executed by a batch runner, the current technology does not permitthe batch runner to pick up the new version of the recipe until theexecution of the original version is completed, even if the execution ofthe original version has not progressed past the point to which thechanges in the recipe apply.

SUMMARY OF THE DISCLOSURE

A batch execution environment operating in a process control systemallows a user to synchronize a running batch with a new version of arecipe being executed by the running batch. The user operates the userinterface tool to select a batch executing an old version of the recipe,interrupt the execution of the selected batch, and resume the operationof the interrupted batch with an updated version of the recipe. In oneembodiment, a batch subsystem receives a new version of a recipe from auser interface tool, saves the new version in a configuration database,and automatically identifies the difference between the new version ofthe recipe and the version of the same recipe currently running in thebatch execution environment. In response to receiving a command from theuser interface tool, the batch subsystem automatically synchronizes thebatch with the new version of the recipe.

In one aspect, the batch subsystem performs resynchronization on demand.In another aspect, the batch subsystem allows automaticresynchronization triggered by a predefined condition. In yet anotheraspect, the user can configure the batch subsystem to automaticallyattempt resynchronization without requesting user's authorization or, byactivating a different option via the user interface tool, the user canlimit resynchronization to manual intervention only. In this case, thebatch subsystem must receive an explicit command from the user prior tosynchronization even if the batch subsystem becomes aware of a newrecipe version.

In one embodiment, the batch subsystem includes one or more batch runnerprocesses with each batch runner executing exactly one batch, a batchmanager process overseeing the operation of each batch runner process,and a batch runtime process detecting changes to recipes. Each batchrunner may be configured to execute a different recipe. In oneembodiment, each batch runner saves event information, such astransitions between steps, operations, and phases, in a persistentlocation. The batch manager reports the event information for each ofthe batch runners to the user interface tool. In another aspect, thebatch manager receives commands from the user interface tools and tellsbatch runners when to start, stop, or hold execution.

In one aspect, a user can make changes to a particular element of anexisting recipe without changing the original name of a unit procedurecorresponding to the element, thus retaining the original high-levellogic of the recipe. In another aspect, a user can use the userinterface tool to update the logic of a recipe currently run by a batchrunner by changing the operands controlling the selection of conditionalsteps. For example, the user may wish to change an OR operand to an ANDoperand or to skip a certain recipe element. In yet another aspect, auser can resynchronize a running batch with a recipe version includingadditional recipe elements.

In one embodiment, a user specifies one or more valid resynchronizationpoints either during recipe configuration or by accessing an existingrecipe at a later time. Each valid resynchronization point is atransition in the original recipe at which the batch can be safelystopped or suspended. As a safety feature, the batch subsystem willprevent the user from re-synchronizing a batch until the batch reachesone of the valid resynchronization points. In another embodiment, thebatch subsystem uses the resynchronization points to perform automaticresynchronization. If configured in a corresponding mode, the batchmanager automatically suspends a batch runner which has reached a validresynchronization point and (if the batch runtime process detects avalid recipe change) applies the new version of the recipe to the batchrunner.

In one embodiment, the batch subsystem automatically detects new recipeversions, determines the difference between recipe versions, andcommunicates the information related to the new recipe elements ortransition to the user interface tool. In some contemplated embodiments,the batch subsystem parses the name assigned to a recipe recently addedto the configuration database to determine whether the new recipe is anew version of an older recipe. The user interface tool the presents alist of recipe elements to the user and visually directs user'sattention to the new recipe elements potentially available forsynchronization.

In another aspect, the batch subsystem additionally receivessynchronization or restart options from the user interface tool after abatch process has been suspended. The synchronization or restart optionstell one or more batch runner whether to run the suspended batch processfrom the beginning (a “cold” restart or synchronize option) or from thepreviously suspended state (a “warm” restart or synchronize option).Moreover, the synchronization or restart options specify whether thebatch process should revert to the previous version of the recipe(“restart”) or apply a new version of the recipe (“synchronize”).

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partial block diagram, partial schematic diagram of aportion of a process control network on which a batch executionenvironment may implement recipe synchronization on demand.

FIG. 2 is a block diagram illustrated the nested structure of a recipeconsistent with the S88 standard.

FIG. 3 is a block diagram illustrating an exemplary architecture of abatch subsystem interacting with the configuration subsystem in a batchexecution environment.

FIG. 4 schematically illustrates online batch synchronization with arecipe version in which one recipe element is updated without a changein the name of the element.

FIG. 5 schematically illustrates online batch synchronization with arecipe version to which a new recipe element has been added.

FIG. 6 schematically illustrates online batch synchronization with arecipe version in which some of the conditional logic has been updated.

FIG. 7 is a block diagram illustrating a high-level interaction betweena recipe configuration subsystem and a batch subsystem during theresynchronization of a batch in an exemplary batch executionenvironment.

FIG. 8 is an exemplary flowchart illustrating a resynchronizationprocedure performed by a system illustrated in FIG. 3.

FIG. 9 illustrates a configuration of valid resynchronization points ofa particular recipe.

FIG. 10 illustrates an exemplary dialogue screen which may be displayedto a user during a manual resynchronization procedure.

DETAILED DESCRIPTION

J Referring now to FIG. 1, a process plant control network 10 includes aprocess controller 12 coupled to numerous workstations 14 via, forexample, an Ethernet communications connection 15. The controller 12 isalso coupled to devices or equipment within a process plant (generallydesignated by the reference numeral 16) via an input/output (I/O) device(not shown) and a set of communication lines or a bus 18. The controller12, which may be by way of example only, the DeltaV™ controller sold byFisher-Rosemount Systems, Inc., is capable of communicating with controlelements, such as field devices and function blocks within field devicesdistributed throughout the process plant 16 to perform one or moreprocess control routines to thereby implement desired control of theprocess plant 16. These process control routines may be continuous orbatch process control routines or procedures. The workstations 14 (whichmay be, for example, personal computers, servers, etc.) may be used byone or more engineers or operators to design process control routines tobe executed by the controller 12, to communicate with the controller 12so as to download such process control routines, to receive and displayinformation pertaining to the process plant 16 during operation of theprocess plant 16 and to otherwise interact with the process controlroutines executed by the controllers 12. Additionally, a data historian19 may be connected to the LAN 15 and may automatically collect andstore data generated within the plant 50, including within thecontroller 12, the filed devices and even the workstations 14, in anyknown or desired manner.

Each of the workstations 14 includes a memory 20 for storingapplications, such as configuration design applications, and for storingdata, such as configuration data pertaining to the configuration of theprocess plant 16. Each of the workstations 14 also includes a processor21 that executes the applications to, among other things, enable a userto design process control routines and download those process controlroutines to the controller 12. Likewise, the controller 12 includes amemory 22 for storing configuration data and process control routines tobe used to control the process plant 16 and includes a processor 24 thatexecutes the process control routines to implement a process controlstrategy. If the controller 12 is a DeltaV controller, it, inconjunction with one or more applications on one of the workstations 14,may provide a graphical depiction of the process control routines withinthe controller 12 to a user illustrating the control elements within theprocess control routine and the manner in which these control elementsare configured to provide control of the process plant 16.

Generally speaking, the process control system of FIG. 1 may be used toimplement batch processes in which, for example, one of the workstations14 executes a batch executive that implements and coordinates differentbatch runs within the process plant 16. In the exemplary process controlsystem illustrated in FIG. 1, such a batch executive 30 resides in theworkstation 14 a. However, the batch executive 30 could be stored andexecuted in other workstations 14, or in other computers communicativelyconnected to the bus 15 or the bus 18 in any desired manner, includingin any wireless manner. Likewise, as discussed in more detail withrespect to FIG. 3, the batch executive 30 may be divided into variouscomponents or be associated with various components stored in andexecuted in different computers or workstations within the process plant16.

Additionally, it will be appreciated that the process plant controlnetwork 10 may include more than one batch executive 30. For example,modern plants currently support up to 4 batch executives sharing some orall of the resources of the process plant control network 10. One ormore batch executives 30 may be generally referred to as a batchsubsystem. By contrast, a configuration subsystem refers to userinterface tools, configuration databases, and other hardware, firmware,and software modules used for defining and editing recipes, monitoringthe performance of batch runs, and other administrative purposes. Itwill be noted that in the present discussion, the terms “batchexecutive” and “batch subsystem” are used interchangeably.

In operation, a user may operate a batch operator interface (“BOI”) 32to define recipes, create batches executing the recipes, and controlbatch execution. Specifically with respect to controlling batchexecution, the BOI 34 may allow users to start, stop, pause, and updatebatch runs. The BOI 34 may interact with the batch subsystem 30 via theEthernet link 15, over a wireless link, or in any other known manner.Although FIG. 1 schematically depicts the BOI 34 as part of theworkstation 14, other implementations and arrangements are equallypossible. For example, the BOI 34 may also run on the workstation 14 a,on a portable device (not shown), or on a host disposed outside theprocess plant control network 10. Further, there may be severalinstances of the BOI 34 instantiated on various hosts in the processplant control network 10 simultaneously supporting multiple operators.Still further, it will be appreciated that the process plant controlnetwork 10 may provide more than one user interface means for accessingrecipe configuration and batch operations. The DeltaV™ system, to takeone example, provides user interface through such components as DeltaVOperate and DeltaV Batch Operator Interface, among others.

Referring again to FIG. 1, a configuration database 34 may store therecipes for the batch subsystem 30, equipment data such as a list ofequipment units in the plant and equipment hierarchy, administrativeinformation related to various areas of the plant, association ofequipment units with plant areas, hierarchical breakdown of equipment,and other configuration data. The configuration database 34 may residein a configuration subsystem separate from the batch subsystem 30. Also,it will be noted that the configuration database 34 may be a separateserver or a group of servers or, if the process plant control network 10is sufficiently small, the configuration database 34 may be implementedsimply as a dedicated process servicing part of the file system of theworkstation 14 or 14 a.

In the example process plant control network 10 illustrated in FIG. 1,the controller 12 is communicatively connected via the bus 18 to twosets of similarly configured equipment, each set of equipment having areactor unit referred to herein as Reactor_01 (R1) or Reactor_02 (R2), afilter unit referred to herein as Filter_01 (F1) or Filter_02 (F2) and adryer unit referred to herein as Dryer_01 (D1) or Dryer_02 (D2).Reactor_01 includes a reactor vessel 100, two input valves 101 and 102connected so as to control fluid inlet lines providing fluid from, forexample, a headtank (not shown) into the reactor vessel 100 and anoutput valve 103 connected so as to control fluid flow out of thereactor vessel 100 via an outlet fluid line. A device 105, which can bea sensor, such as a temperature sensor, a pressure sensor, a fluid levelmeter etc. or some other equipment such as an electrical heater or asteam heater, is disposed in or near the reactor vessel 100. TheReactor_01 is coupled via the valve 103 to the Filter_01 having filterequipment 110 which, in turn is coupled to the Dryer_01 having dryerequipment 120. Similarly, the second set of equipment includes theReactor_02 which has a reactor vessel 200, two input valves 201 and 202,an output valve 203 and a device 205. The Reactor_02 is coupled to theFilter_02 having filter equipment 210 which, in turn, is coupled to theDryer_02 which has dryer equipment 220. The filter equipment 110 and 210and the dryer equipment 120 and 220 may have additional control elements(such as heaters, conveyor belts and the like), sensors, etc. associatedtherewith. If desired, although not shown, each of the filter unitsFilter_01 and Filter_02 may be physically coupled to each of the reactorunits Reactor_01 and Reactor_02 while each of the dryer units Dryer_01and Dryer_02 may be coupled to each of the filter units Filter_01 andFilter_02 so that a batch run using one of each of a reactor, a filterand a dryer may use any combination of the equipment illustrated in FIG.1.

As illustrated in FIG. 1, the controller 12 is communicatively coupledto the valves 101-103, 201-203, to the devices 105, 205, to the filters110, 210 and to the dryers 120 and 220 (and to the other equipmentassociated therewith) via the bus 18 to control the operation of theseelements (which may be units, field devices, etc.) to perform one ormore operations with respect to these elements. Such operations mayinclude, for example, filling the reactor vessels, or dryers, heatingthe material within the reactor vessels or dryers, dumping the reactorvessels or dryers, cleaning the reactor vessels or dryers, operating thefilters, etc. Of course, the controller 12 could be coupled to theelements within the process plant 16 via additional busses, viadedicated communication lines, such as 4-20 ma lines, HART communicationlines, etc.

The valves, sensors and other equipment illustrated in FIG. 1 may be anydesired kind or type of equipment including, for example, Fieldbus fielddevices, standard 4-20 ma field devices, HART field devices, etc. andmay communicate with the controller 12 using any known or desiredcommunication protocol such as the Fieldbus protocol, the HART protocol,the 4-20 ma analog protocol, etc. Still further, other types of devicesmay be connected to and be controlled by the controller 12 in anydesired manner. Also, other controllers may be connected to thecontroller 12 and to the workstations 14 via, for example, the Ethernetcommunication line 15 to control other devices or areas associated withthe process plant 16 and the operation of such additional controllersmay be coordinated with the operation of the controller 12 illustratedin FIG. 1 in any desired or known manner.

A user may configure recipes, form equipment trains from process controlequipment such as devices valves 101-102 and a vessel 100, associate theequipment trains with batches and interact with the batch subsystem 30via the BOI 34 or other interface tools. The BOI 34 may retrieve thestatus of each batch running in the system either periodically or inreal time. The batch execution environment of the network 10 and, inparticular, the batch subsystem 30 working in cooperation with the BOI34 and the configuration database 34, allows the user to select arunning batch, temporarily suspend the batch, view the recipe beingexecuted by the batch, and make changes to the recipe either on a highlevel or in one of the lower layers by “drilling into” recipe elements.The user may then save the updated recipe to the configuration database34, and optionally request the batch subsystem 30 to resynchronize thesuspended batch with the new version of the recipe according to one ofthe selected resynchronization options. The modules and methods involvedin synchronizing and executing new recipe versions with the runningbatches are discussed in detail below in reference to FIGS. 3-11.

The batch subsystem 30 includes a high level control routine thatenables a user to specify a number of batch runs to be performed withinthe process plant and that sets up a number of different batch runs orbatch processes to operate essentially independently within the processplant control network 10 to implement the different batch runs. Eachsuch batch process directs the operation of one or more unit procedures,which are sub-routines or processes that operate on a single unit, suchas one of the reactor units, the filter units, the dryer units, or otherequipment within the process plant. Each unit procedure (which is a partof a batch run that is generally run on one of the workstations 14) mayperform a series of operations, each of which may perform one or morephases on a unit. For this discussion, a phase is the lowest levelaction or step performed on a unit and is typically implemented orexecuted in one of the controllers 12, an operation is a set of phasesthat performs a particular function on the unit and is typicallyimplemented or executed on one of the workstations 14 by calling aseries of phases within the controller 12, while a unit procedure is aseries of one or more operations performed on a single unit and istypically implemented as a set of operation calls on one of theworkstations 14. As a result, any unit procedure can include one or morephases and/or one or more operations. In this manner, each batch processperforms different steps or stages (i.e., unit procedures) needed toproduce a product, such as a food product, a drug, etc.

To implement different unit procedures, operations and phases for anindividual batch, a batch process uses what is commonly referred to as arecipe which specifies the steps to be performed, the amounts and timesassociated with the steps and the order of the steps. Steps for onerecipe might include, for example, filling a reactor vessel with theappropriate materials or ingredients, mixing the materials within thereactor vessel, heating the materials within the reactor vessel to acertain temperature for a certain amount of time, emptying the reactorvessel and then cleaning the reactor vessel to prepare for the nextbatch, running a filter to filter the output of a reactor and thenrunning a dryer to dry the product created in the reactor vessel. Eachof the series of steps associated with a different unit defines a unitprocedure of the batch and the batch process will execute a differentcontrol algorithm for each one of these unit procedures. Of course, thespecific materials, amounts of materials, heating temperatures andtimes, etc. may be different for different recipes and, consequently,these parameters may change from batch run to batch run depending on theproduct being manufactured or produced and the recipe being used. Thoseskilled in the art will understand that, while control routines andconfigurations are described herein for batches using the reactor units,the filter units and the dryer units illustrated in FIG. 1, controlroutines may be used to control other desired devices to perform anyother desired batch process runs or to perform continuous process plantruns, if so desired.

As will also be understood by those skilled in the art, the same phases,operations or unit procedures of a generic batch process can beimplemented on each of the different reactor units of FIG. 1 at the sameor at different times as part of different actual batch processes.Furthermore, because the reactor units of FIG. 1 generally include thesame number of and types of equipment (i.e., they belong to the sameunit class), the same generic phase control routine for a particularphase may be used to control each of the different reactor units, exceptthat this generic phase control routine has to be modified to controlthe different hardware or equipment associated with the differentreactor units. For example, to implement a fill phase for Reactor_01(wherein the reactor unit is filled), a fill control routine will openone or more of the input valves 101 or 102 for a certain amount of time,for example, until the fluid level meter 105 senses that the vessel 100is full. However, this same control routine may be used to implement afill phase for Reactor_02 by merely changing the designation of theinput valve(s) to be the valves 201 or 202 instead of the valves 101 or102 and by changing the designation of the fluid level meter to be thefluid level meter 205 instead of the fluid level meter 105.

Although the logic associated with the general operation of batch runsis well known, FIG. 2 provides a summary overview of a recipe structurerelevant to the method of online recipe synchronization in a batchexecution environment. A recipe 250 is compliant with the hierarchicalstructure of the S88 standard. However, one skilled in the art willappreciate that the method of online recipe synchronization may alsoapply to other existing and future recipe definition standards. Asillustrated in FIG. 2, the recipe 250 includes one or more steps, suchas steps 253 and 255, separated by transitions 257. Each of the steps ofthe recipe 250 may have a complex internal structure and may be definedas a separate unit procedure. For example, the step 255 may be definedas a unit procedure 260.

The transition 257 may specify a condition which must be met within thestep 253 prior to performing the step following the transition 257 (inthis case, the step 255). For example, the step 253 may perform a mixingof two chemicals the condition 257 may check whether the mixing hasexceeded a 2-minute time limit. As another example, the transition 257may be set to Boolean “true” in order to affect transition regardless ofthe result of executing step 253. In general, the conditions may besimple or compound, and may include Boolean operands such as “and” and“or.” The unit procedure 260 may, in turn, include one or moreoperations 263 or 265 similarly separated by conditions 257. In theexample illustrated in FIG. 2, the operation 263 is implementedaccording to an operation definition 270. The operation definition 270may include or more phases 272 and 274 separated by conditions 257.

A user may create recipes such as the recipe 250 a dedicated software onone of the workstations 14 or 14 a. In some embodiments, the softwarecreation software is provided as part of the BOI 32. One such softwarepackage is the Recipe Studio provided as part of the DeltaV™ system. Inaddition to assigning a name to the recipe 250, the user may associatethe recipe with a certain version. In other words, the user may createan initial version of the recipe 250, assign the name“Chocolate_Cookie_001” to the recipe 250 and associate a versionidentifier “v1” with the recipe 250. At a later time, the user maycreate another version of the same recipe 250 and associate the newversion with a version identifier “v2,” for example. In one embodiment,the configuration database 34 may contain two recipes with the same namebut different version identifiers. In another embodiment, the user maysimply save the new version under the same name as the previous version.

In either case, new recipe versions always arrive from the userinterface 32 or other recipe creation tool at the configuration database34 via the batch subsystem 30. In other words, the batch system 30passes recipe information between the user and the configurationdatabase 34 so that the batch system 30 is always aware of the changesto the existing recipe versions. In this manner, the batch system 30 maysynchronize the new recipe versions with batches running within thesubsystem 30 when necessary. In another embodiment, the user interface32 interacts with the configuration database 34 directly. In order toautomate at least some aspects of recipe resynchronization (as discussedin greater detail below), the user interface 32 or the configurationdatabase 34 includes a software routine duplicating recipe informationfor the batch subsystem 30. As yet another alternative, the userinterface 32 directly interacts with the configuration database 34 andthe batch system 30 periodically requests updates from the configurationdatabase 34. For example, the batch system 30 may run a backgroundprocess waking up according to a predefined timeout value in order toinquire whether new versions of the recipes being executed by the batchsystem 30 have become available at the configuration database 34 sincethe last inquiry. However, one skilled in the art will appreciate thatby placing the batch subsystem 30 between the user interface tools andthe configuration database 34, the batch execution environment may beimplemented more efficiently.

FIG. 3 illustrates an exemplary architecture of a batch subsystem 30 ina process plant control network 10. The batch subsystem 30 may interactwith a user interface tool such as the BOI 30 via the Ethernetcommunications connection 15 or, if the batch subsystem 30 and the userinterface 30 reside on the same workstation 14 or 14a, via one of theknown inter-process communication (IPC) means. The batch subsystem 30may include a batch manager 282, a batch runtime process 284, and one orbatch runners 286-290. Each of the components of the batch subsystem 30processes may be implemented as an independent process or a thread. Asindicated above, the batch subsystem 30 may be distributed over severalworkstations or other hosts.

Each of the batch runners 286-290 executes exactly one batch. Some ofthe batch runners 286-290 may run the same recipe such as, for example,the recipe 250. It will be appreciated that the batch runners 286-290need not be in the same state of execution at all times even if each ofthe batch runners is executing the same recipe. In the exampleillustrated in FIG. 3, the batch runner 290 is connected to thecontroller 12 via the Ethernet connection 15. In operation, the batchrunner 290 may execute the logic on the level of unit procedures andoperations in the process space on the corresponding workstations 14 or14 a. However, the batch runner 290 loads the phases 272 and 274 of eachoperation into the controller 12.

Referring again to FIG. 3, a persistent storage unit 292 may retainstate, transition, and parameter information related to each of thebatch runners 286-290. The persistent storage 292 may be a hard diskdrive of one of the workstations 14 or 14 a, an external storage devicesuch as a CD or DVD, or other known data storage devices. The batchmanager 282, the batch runtime process 284, and each of the batchrunners 286-290 may access to the persistent storage 292 via theEthernet connection 15 or through IPC calls if the persistent storage292 resides on the same host. In operation, each of the batch runners286-290 saves information related to the execution status of thecorresponding batch. For example, the batch runner 290 may record thestate of the currently running unit procedure, operation, and phase.Thus, a record in the persistent storage unit 292 may at some pointindicate that the batch runner 290 is currently executing step 3,operation 1, phase 2 of the recipe 250. Additionally, the record mayspecify the state of the each of the levels, such as RUNNING, HELD, orABORTED, for example. Further, the batch runner 290 may record thevalues of parameter passed into a unit procedure, operation, and phase.The batch runner 290 preferably updates the persistent storage unit 292in substantially real time.

Additionally, the batch runner 290 may record each transition 257between, for example, steps 253 and 255, operations 263 and 265, andphases 272 and 274. The transition may be recorded in the persistentstorage 292 along with the state and parameter information.Alternatively, state transitions may be recorded as separate event logsstored in the data historian 19. Even logs may also include some or allof the parameter information and such additional information astimestamps associated with each transition, error conditions, and otherinformation useful for monitoring or debugging the system in post-time.The even logs may similarly store synchronization indications. Forexample, a certain record in the even log may indicate that the batchrunner 290 resynchronized with the version v2 of a recipe“Chocolate_Cookie_001” at step 3, operation 1, phase 1 at 14:25 p.m. onSeptember, 21.

As indicated above, the batch manager 282 controls the execution of thebatch runners 286-290. In particular, the batch manager 282 sendscommands to the batch runners 286-290 indicating to the batch runnerswhen to start, stop, or pause execution. Additionally, the batch manager282 reports the status of each of the batch runners 286-290 to anoperator via the user interface tool 280. For example, the batch manager282 may access the persistent storage 292 to retrieve the state of thebatch runner 290 and may report the state to the interface tool 280 inform of a message consistent with a well-known format such as XML or aspecial purpose format defined specifically for the interaction betweenthe elements of the batch subsystem 30. In this sense, the batch manager282 serves as a centralized gateway to all batch runners.

In one embodiment, the batch manager 282 and the batch runners 286-290additionally have access to a shared memory region storing copies of therecipe currently being executed by the batch subsystem 30. The sharedmemory region may be a persistent or volatile memory location and may bedisposed inside or outside the batch subsystem 30. In some embodiments,the batch manager 30 saves a copy of each recipe prior to triggering arun of the recipe by one of the batch runners 286-290. In anotherembodiment, an individual batch runner saves a copy of the recipe in itsown process space or in a permanent location unknown or inaccessible tothe rest of the batch subsystem 30. In either case, the batch subsystem30 may store each recipe as a single file or as an hierarchicalstructure of elements. Preferably, the batch manager 282 and each of thebatch runners 286-290 have means of accessing individual recipe elementssuch as unit procedures, operations, and phases for reading and writing.

Meanwhile, the batch runtime process 284 serves as an interface with therest of the process plant control network 10. In particular, the batchruntime 284 may interact with the configuration database 34 throughrecipe download scripts. In one embodiment, the user interface 32packages recipes in XML in order to allow for both human and machinereadability. Alternatively, the user interface 32, the batch subsystem30, and the configuration database 34 may send script information overany standard or proprietary protocol. The batch runtime process 284 maybe also responsible for such functions as maintaining system securityand log maintenance. Moreover, the batch runtime process 284 may recordstart, stop, and other relevant high-level information in the persistentstorage 292 or in the configuration database 34.

Further, the batch runtime process 284 may identify the changes to aparticular recipe relative to an earlier version of the same recipe. Forexample, a single small parameter of certain operation, such as theamount of time a mixer should run, may change from 25 minutes to 30minutes. Upon receiving a new, 30-minute version of the recipe, thebatch runtime process 284 may first send a query the batch manager 282to check whether any of the batch runners 286-290 are currently runningthe old version of the same recipe. In one embodiment, the batch runtimeprocess 284 and the batch manager 286 may simply compare the names ofthe recipes in order to determine whether the new recipe is currentlybeing run in the batch subsystem 30. To this end, the batch manager 286may store the name or other unique identifier of a recipe for eachactive batch runner. In response to the query from the batch runtimeprocess 284, the batch manager 286 may indicate, for example, that therecipe is applicable to one or more of the active batch runners 286-290.The batch runtime process 284 may then retrieve the original recipe fromthe configuration database 34 and perform a comparison between the newand the old recipe versions. Alternatively, the user interface 32 maygenerate and propagate a “marked-up” copy of the recipe identifying thechanges made by the user.

As indicated above, recipe updates may fall into one of the severalcategories depending on the extent of changes made by the user. FIG. 4illustrates an exemplary update scenario which includes a modificationinside of the unit procedures without a change to the name of the unitprocedure. It will be appreciated that this scenario is also analogousto a case in which the modification is made inside an individualoperation retaining the original operation name. As illustrated in FIG.4, both the new and the old versions of the recipe 300 include a step302 followed by a transition 304, followed by a step 306. However, theuser may have updated the unit procedure corresponding to the step 310and may request the subsystem 30 to execute the step 312 instead of thestep 310 once the corresponding batch reaches the transition 308. Thestep 312 differs from the step 310 only in the version of the executedunit procedure.

In some embodiments of the batch execution environment and, inparticular, of the batch subsystem 30, a user may wish to avoid saving anew version of a recipe or recipe element under the same name. In somecases, users may not be allowed to duplicate the existing recipe orprocedure names as a matter of policy. In this and similar situations,the user interface 32 may automatically generate a new name of the unitprocedure, such as UPROC_MIX_INGREDIENTS_012_V02, to differentiate thenew version of the recipe 300 from the previous version namedUPROC_MIX_INGREDIENTS_012_V1. The name is such that a machine script mayeasily parse the name and extract the version number and otheridentifiers.

Meanwhile, the scenario illustrated in FIG. 5 includes an addition of anew recipe element to a recipe 320. In particular, the new version ofthe recipe 320 requires that a step 322 be followed by a new step 324and a transition 326. The transition 326 directs the flow of the recipe320 back to an original step 328. It will be appreciated that thescenario illustrated in FIG. 5 differs from manually executing a phasewithin the scope of an existing batch. In particular, the new step 324is connected to the existing steps 322 and 328 by means of S88-complianttransitions. In other words, the user need not manually controltransitions after adding new recipe elements. Moreover, the procedurestep 324 becomes a part of the recipe 320 and, as a result, the eventfrom the new step 324 may be collected as part of batch running therecipe 320.

Referring to FIG. 6, a new version of a recipe 350 includes a change inrecipe logic following a step 352. In particular, the new version therecipe 350 changes the condition 354 (“OR”) to condition 356 (“AND”). Inthis scenario, the unit procedures of the recipe 350 may not change atall. However, the user may decide, for example, to try adding bothchocolate (step 360) and vanilla (step 362) to ice cream produced by abatch executing the recipe 350 instead of selecting one of chocolate andvanilla according to the previous version of the recipe 350.

In the scenarios described above in reference to FIGS. 4-6, thesubsystem 30 may keep the previous version of the recipe 300, 320, or350 in a persistent or volatile memory because one of the batch runners286-290 may be currently executing this recipe. In one embodiment, thebatch runtime process 284 may notify the batch manager 282 with the nameor unique identifier of the updated recipe 300, 320, or 350 and,additionally, with a list of specific elements updated in the recipe 300on the unit procedure or operation level. The batch manager 282 mayindicate to the batch runner 286 executing the recipe 300, for example,that the batch execution must be suspended upon reaching the transition308. The batch manager 282 may then update either the entire copy of therecipe 300 or the copy of the unit procedure corresponding to the step310 saved in the batch subsystem 30.

However, the batch manager 282 need not always synchronize each of thebatch runners 286-290 running the recipe 300 upon being notified that anew version of the recipe 300 is available and the differences have beenprocessed by the batch runtime process 284. Importantly, a user mayselect which of the batch runners 286-290 should synchronize with thenew recipe version and which should continue executing the originalrecipe either until completion or until receiving a new abort or suspendcommand from the user. In this respect, online recipe resynchronizationsupported by the batch subsystem 30 in cooperation with theconfiguration subsystem of the process plant control network 10 allowsusers to “try out” new recipe versions on a controlled scale prior toadapting the new recipe version across the entire batch subsystem 30 orthe entire process plant 16.

FIG. 7 illustrates one such contemplated scenario in more detail. Inthis example, the user operates the user interface software such as theBOI 32 to create a first version of a certain recipe (block 380). Atthis point, the user may be planning to run two parallel batches withthe first version of the recipe. The user interface 32 passes recipe tothe batch subsystem 30 via the batch runtime process 284. In addition tosaving the recipe in the configuration database 34, the batch runtimeprocess 284 passes the first version of the recipe to the batch manager282 which, in turn, applies the recipe to the available batch runners286 and 288 (step 382). The recipe is loaded into batch runners 286 and288 in blocks 384 and 386, respectively.

The batch manager 282 may then trigger the execution of the recipe inthe batch runners 286 and 288. In a block 388, the batch runner 286 maystart executing the steps of the recipe and the batch runner 288 maysimilarly begin batch execution in a block 390. Meanwhile, the user maydecide that the recipe may be improved by one or more relatively smallchanges to the original version. To this end, the user may create a newversion of the recipe in a block 392. Moreover, the user may want thechanges to go into effect as soon as possible. At the same time, theuser may be concerned about applying the new recipe across the entirebatch subsystem 30 and may deem it more prudent to apply the recipe toonly one of the batches first.

In some embodiments, the user may know the precise state each batchrunner is in. In other embodiments, the batch interface 32 mayselectively present state and transition information to users dependingon the users' access privileges or profile configuration. While the usermay not always know whether the execution of the recipe has alreadyprogressed passed the point at which resynchronization is stillpossible, the user may nevertheless instruct the user interface 32 tosave the new version of the recipe under the original recipe name orunder a name accurately reflecting the recipe version, place the batchrunner 286 on hold by typing in a command from a prompt or by operatinga visual control on the batch interface 32, and request the batchsubsystem 30 to synchronize the batch runner 286 with the new version.

Alternatively, the user may instruct the user interface 32 to apply thenew version to the batch subsystem 30 wherever possible. Of course, bothoptions also may be made available in the same embodiment of the batchsubsystem 30. Moreover, it is contemplated that resynchronization may beprovided as a single control which may automatically interact with thebatch subsystem 30 to determine to which batch runners, if any, the newrecipes applies, and automatically place the relevant batch runners onhold. Further, the user interface 32 may display a confirmation dialogueto the user informing him or her about the batch processes whichpotentially may be synchronized with the new recipe version.

The batch interface 284 may determine which changes to the first versionof the recipe may apply to the batch runner 286 and pass the relevantupdate information to the batch runner 286 (directly or via the batchmanager 282). The batch runner 286 may delete the original version ofthe recipe from the corresponding memory location, save the new version,identify the step to be executed next, and wait from the user interfaceto propagate a command from the user (not shown) telling the batchrunner 286 to resume execution (block 396). As will be discussed below,the user may provide additional instructions to the batch subsystem 30regarding the particular step in the recipe from which the batch runner286 may resume execution. The batch runner 286 may continue theexecution if synchronization is successful. However, the user may havechanged the original version of the recipe in an erroneous or illegalmanner. Upon encountering an invalid transition, a missing step, orother abnormal situation, the batch runner 286 may change its stateRESYNCHRONIZATION_FAILED, for example. In some contemplated embodiments,the batch runner 286 may automatically revert to a previous (stable)version of the recipe. In another embodiment or in accordance withanother configuration option, the batch runner 286 may sometimes attempt“cold resynchronization,” or starting the new recipe from the firststep.

In blocks 398 and 400, the batch runners 286 and 288 may complete therespective batches. The user may evaluate the results of batch executionin a block 402 and may decide if the batch runner 286 should revert tothe original recipe version or if the new version of the recipe shouldbe applied to the batch runner 288 as well. In particular, the batchrunner 286 may fail to fully execute the new untested version of therecipe. In this case, the batch subsystem may automatically change thestatus of the batch to HELD or similar state indicative of suspendedexecution. The user interface 32 may, in turn, generate an interactivedialogue displaying the question “Revert to the previous version?Yes/No?”

FIG. 8 is an exemplary flowchart illustrating a resynchronizationprocedure 420 distributed over the batch subsystem 30 and parts of theconfiguration subsystem such as the user interface 32. In a block 422, auser may retrieve a recipe from the configuration database 34 and createa new version of the recipe. In a block 424, the BOI 32 may display alist of currently active batches, a state of each batch, and recipeinformation for each active batch. The user may select one of thebatches in a block 426 and change the operational state of the batch toSTOPPED or ABORTED in a block 430. In the example illustrated in FIG. 8,the user selects a batch running an older version of the recipe updatedin the block 422.

The user may choose whether to continue running the original version ofthe recipe or start a new version in a block 432. If the user decides toresynchronize the suspended batch, the procedure 420 may proceed to ablock 434. In the block 434, the batch manager 282 may identify thebatch runner executing the suspended batch and apply the recipe updatesto the identified batch runner. As discussed above, the step 434 mayalso include saving the new recipe version in the configuration database34, comparing the old and new versions of the recipe in the batchruntime process 284, and communicating the necessary information relatedto the changes to the batch manager 282.

In a block 436, the user may select between cold and warm restartoptions. In particular, cold restart results in the batch run startingfrom the first step in the recipe. On the other hand, warm restartallows the batch to resume at the current step of the recipe. The usermay select the warm restart option when the new version properly alignswith the original recipe so that a transition to one or new updated ornew steps does not result in an illegal condition. Referring back toFIG. 4, the user may select warm restart in order for the batch runnerto seamlessly continue on to the step 312 after the transition 308.Thus, the procedure 420 may first attempt to align recipes in ablock/step 438. As part of the step 438, the procedure 420 may identifywhich step of the recipe the batch is currently executing or whichtransition the batch has reached, locate the step or transition in thenew recipe, and determine whether is in fact possible and allowable.

To prevent serious errors, the procedure 420 may consider changes in anactive step of the batch to be illegal and may prohibitresynchronization in the active steps as a matter of policy. Forexample, if a certain batch is currently executing step 2/operation1/phase 3 of a certain recipe, the procedure 420 may not allow the batchto resynchronize with a new version of the recipe if the change effectsthe same phase 3 within step 2/operation 1, or if the change effects thename of operation 1 within step 2, or in similar potentially contentioussituations. Additionally, the procedure 420 may validate procedure andoperation parameters to ensure that the new recipe does not requirevalues which are unavailable. To take one example, the recipe may updatethe unit procedure 2 which requires 3 parameters in the newconfiguration. Meanwhile, the batch may be executing one of theoperations within the unit procedure 2 which requires only 2 parametersin the current configuration. Thus, synchronizing the batch at thispoint impermissibly requires that another parameter be added at anearlier stage of execution of the batch (i.e., at the point where thebatch enters and supplies parameters to the unit procedure 2.

Because the user may inadvertently create a condition which violates thelogic of recipe execution, the procedure 420 may instead look for avalid synchronization point later in the recipe or may simply place thebatch in the SYNCHRONIZATION_FAILED state. The user may then resume therun using the original recipe version or initiate a cold restart usingthe new recipe. If, on the hand, the synchronization is determined tovalid, the procedure 420 may indicate to the user that thesynchronization is complete and that the batch may be resumed. In ablock 440, the user may send an appropriate command to the batchsubsystem 30 and, upon receiving the command, the procedure 420 mayadvance the batch to the RUNNING state and the batch may continueexecution.

The batch subsystem 30 may also support automatic synchronization withnew recipe version via a pause location lists. As illustrated in FIG. 9,a recipe 500 includes several steps separates by transitions 502-508.Generally speaking, a recipe such as the recipe 500 may have severaltransitions on the batch procedure, unit procedure, and operation level.As discussed above, the user may create the recipe 500 by using theDeltaV™ Recipe Studio tool or similar means. In addition to specifyingrecipe elements and transitions, the user may supply a list 510associated with the recipe 500 which includes zero or more validresynchronization points. Alternatively or additionally, the subsystem30 and the user interface 32 may allow users to define the list 510 foran active batch already executing the recipe 500. In a situation wherean operator discovers a problem with the recipe 500 and realizes thatthere is at least one more batch executing the same recipe but runningseveral steps behind the problem batch, for example, the operator maywish to define a pause location list on the fly.

In the example illustrated in FIG. 9, the list 510 includes twotransition identifiers 512 and 514. The transition identifier 512 maycorrespond to the transition 502 while the transition identifier 514 maycorrespond to the transition 506. By adding the transition identifiers512 and 514 to the list 510, the user requests that the execution of therecipe 500 be suspended upon reaching the transitions 502 and 506. Inother words, the transitions 502 and 506 are always disabled. In orderfor a batch executing the recipe 500 to resume and for the transition502 to 506 to fire, the batch subsystem 30 must receive an explicitcommand from the user.

It is also contemplated that the subsystem 30 may automaticallysynchronize the batch executing the recipe 500 upon reaching each of thetransitions 502 and 506. To this end, the user 32 may provide a control,such as a dialogue box or a command prompt, permitting a user to selectbetween manual and automatic synchronization modes. A user may preferthe automated mode when he or she knows, for example, that a new versionof a recipe should unconditionally supersede all previous versions andthat the new version may become available at a time when the operatormay not be available for a manual update. In response to detecting thatthe user has selected the automatic mode, the batch subsystem mayinterrupt the execution of the recipe 500 at the transitions 502 and506, check whether updates are available at the configuration database34 and, if a new version is available, apply the new version to one ormore corresponding batch runners. The batch subsystem may then recordthe event in the data historian 14 and resume the execution from thesuspended the same state (i.e., perform warm resynchronization).

Referring to FIG. 10, the batch runtime process 284 may periodicallyquery the configuration database 34 to detect changes to recipes. Thebatch subsystem 30 may provide indications to the user interface 32regarding the detected changes. As one skilled in the art willrecognize, there may be many operators and engineers configuring andsupervising a process plant control network 10. As a result, engineersmay create new versions of recipes and some operators may not be awarethat the updates are available. In order to minimize the impact ofmissed human communications, the user interface 32 may use visualindicators in batch configuration and control tools such as an exemplarywindow 550.

In particular, the window 550 may include a list of currently runningbatches 555. Preferably, the user may invoke the window 550 from everysoftware module running in the process plant control network 10 andadapted for viewing or configuring the batch execution environment. Forexample, the DeltaV™ environment may provide window 550 as part of theBatch Operate software as well as part of the Batch OperationalInterface software.

For each active batch, the list 555 may include a batch identificationindicator 557, a recipe identification indicator 559, and a stateindicator 561. Additionally, the window 550 may include batch operationcontrol such as start, stop, and hold buttons 565. Further, by operatinga button 567, the user may place the operation of a selected batch undermanual control. Still further, the user may synchronize the selectedbatch by operating the button 569. In order for the user to effectivelyinvoke start, stop, hold, and resynchronization options, the list 555may include an update indicator 570. As illustrated in FIG. 10, theupdate indicator 570 may be activated in a line corresponding torecently updated recipe. For example, the recipe 001 may have beenupdated after the batch 001 was started but the operator may not beaware of the update.

The user may double-click on the line showing the update indicator 570or invoke a detailed recipe window 575 in a similar manner. The detailedrecipe window 575 may highlight or otherwise identify one or more partsof the recipe in which the batch runtime process 284 has detected one ormore changes. In the example illustrated in FIG. 10, the recipe element580 included in the recipe currently executed by the batch 001 isdifferent from the new version. The user may view the changes to therecipe element 580 and synchronize the recipe 001 in a manual orautomated manner.

While the present invention has been described with reference tospecific examples, which are intended to be illustrative only and not tobe limiting of the invention, it will be apparent to those of ordinaryskill in the art that changes, additions or deletions may be made to thedisclosed embodiments without departing from the spirit and scope of theinvention.

1. A method of executing a batch process in a manufacturing environmentaccording to a product recipe, wherein the product recipe specifies aplurality of actions and a plurality of parameters, the methodcomprising: performing at least one action of the batch processcorresponding to a first version of the product recipe; receiving asecond version of the product recipe, wherein the second version of theproduct recipe is distinct from the first version of the product recipe;suspending the execution of the batch process prior to completion of thebatch process; and selecting whether to resume the execution of thebatch process according to the first version of the product recipe orthe second version of the product recipe based on a comparison betweenthe first version of the product recipe and the second version of theproduct recipe; resuming the execution of the batch process according tothe selected version of the product recipe.
 2. The method of claim 1,wherein executing the batch process according to the product recipeincludes executing a plurality of steps, each step corresponding to aunit procedure comprising at least one operation, each operation havingat least one phase; and wherein the batch process transitions from afirst one of the plurality of steps to a second one of the plurality ofsteps when a condition associated with the first one of the plurality ofsteps is met.
 3. The method of claim 2, wherein receiving the secondversion of the product recipe includes receiving the second version ofthe product recipe that differs from the first version of the productrecipe in at least one of a unit procedure, an operation, or a phase. 4.The method of claim 2, wherein executing the batch process according tothe product recipe includes executing the batch process according to theproduct recipe consistent with the ANSI/ISA-88 (S88) standard.
 5. Themethod of claim 1, further comprising: receiving configuration dataspecifying at least one synchronization point of the batch process,wherein the at least one synchronization point corresponds to atransaction between two or more of the plurality of actions of the firstversion of the product recipe at which the batch process can besuspended.
 6. The method of claim 5, wherein selecting whether to resumethe execution of the batch process according to the first version of theproduct recipe or the second version of the product recipe includesautomatically selecting the second version of the recipe upon reachingthe at least one synchronization point.
 7. The method of claim 5,wherein receiving the configuration data includes receiving theconfiguration data prior to performing at least one action of the batchprocess; wherein suspending the execution of the batch process includes:suspending the execution of the batch process when the at least onesynchronization point is reached; and reporting the suspension of theexecution of the batch process to a user interface; and whereinselecting whether to resume the execution of the batch process accordingto the first version of the product recipe or the second version of theproduct recipe further includes: selecting the first version of therecipe in response to receiving a first command from the user interface;and wherein selecting in response to receiving a second command from theuser interface.
 8. The method of claim 5, wherein receivingconfiguration data includes receiving configuration data specifying aplurality of synchronization points, wherein suspending the execution ofthe batch process includes suspending the execution of the batch processeach time one of the plurality synchronization points is reached;initiating a query to detect availability of the second version of therecipe; and selecting whether to resume the execution of the batchprocess according to the first version of the product recipe or thesecond version of the product recipe includes selecting the firstversion of the recipe if the second version of the recipe is notavailable.
 9. The method of claim 1, wherein selecting whether to resumethe execution of the batch process according to the second version ofthe product recipe includes receiving a confirmation from an authorizeduser.
 10. The method of claim 1, further comprising saving eventinformation in a persistent memory, wherein the event informationcorresponds to a completion of one or several of the plurality ofactions.
 11. The method of claim 1, wherein receiving the second versionof the product recipe includes: comparing the second version of therecipe to the first version of the recipe to generate a reportindicative of a difference between the first version of the recipe andthe second version of the recipe; and sending the report to a userinterface.
 12. A system for controlling a batch process executing in amanufacturing environment according to a product recipe that specifies aplurality of actions, the system comprising: a batch runnercommunicatively connected to process control equipment to execute thebatch process thereon; a batch manager communicatively connected to thebatch runner to control the batch runner via at least a first command tostart the batch process and a second command to stop the batch process;and a batch runtime module to detect a modification to the recipe and toreport data indicative of the detected modification to the batchmanager; wherein the batch manager is operable to determine whether toapply the modified recipe to the batch runner based on whether themodified recipe is selected and is operable to apply the change in therecipe to the batch runner prior to the batch runner completing theexecution of the batch process if the batch manager determines themodified recipe should be applied based on a comparison between therecipe and the modified recipe.
 13. The system of claim 12, wherein therecipe includes a plurality of unit procedures; and wherein themodification to the recipe includes an addition of a new unit procedureto the recipe.
 14. The system of claim 12, wherein the recipe includes aplurality of unit procedures; wherein the modification includes a changeto at least one of the steps of one of the plurality of unit procedures;and wherein the one of the plurality of unit procedures is assigned anew version identifier associated with the original name of the one ofthe plurality of unit procedures.
 15. The system of claim 12, whereinthe modification includes a change to a logical operand associated witha transition between two of the plurality of actions.
 16. The system ofclaim 12, further comprising a persistent memory to store event dataindicative of transitions between the plurality of actions.
 17. Thesystem of claim 12, further comprising a user interface communicativelyconnected to the batch manager, the user interface including a firstfunction to receive a user request to synchronize the recipe with a newversion of the recipe including the modification and to select themodified recipe for application to the batch runner.
 18. The system ofclaim 17, wherein the user interface further includes: a second functionto provide a list of active batch runners to the user; and a thirdfunction to receive from the user a selection of an active batch runnerfrom the list of active batch runners.
 19. The system of claim 17,wherein the user interface further includes: a second function tovalidate user authentication information prior to selecting the modifiedrecipe for application to the batch runner.
 20. The system of claim 17,wherein the user interface further includes: a second function toreceive configuration data specifying a set of synchronization points ofthe recipe, wherein each one in the set of synchronization pointscorresponds to a respective transaction between two of the plurality ofactions of the recipe at which the batch runner can be suspended. 21.The system of claim 12, further comprising: a validation module todetermine whether the modification violates a logic of the recipe and togenerate a validity indicator; wherein the batch manager applies thechange in the recipe to the batch runner only if the validity indicatoris not indicative of a violation of the logic.
 22. The system of claim12, wherein the batch runtime module generates a report indicative ofthe modification to the recipe and transmits the generated report to auser.